Note: Descriptions are shown in the official language in which they were submitted.
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SYSTEM FOR LINING A WELLBORE CASING
Background
[004] This invention relates generally to wellbore casings, and in particular
to wellbore casings that are
formed using expandable tubing.
[005] Conventionally, when a wellbore is created, a number of casings are
installed in the borehole to
prevent collapse of the borehole wall and to prevent undesired outflow of
drilling fluid into the formation or
inflow of fluid from the formation into the borehole. The borehole is drilled
in intervals whereby a casing
which is to be installed in a lower borehole interval is lowered through a
previously installed casing of an
upper borehole interval. As a consequence of this procedure the casing of the
lower interval is of smaller
diameter than the casing of the upper interval. Thus, the casings are in a
nested arrangement with casing
diameters decreasing in downward direction. Cement annuli are provided between
the outer surfaces of
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the casings and the borehole wall to seal the casings from the borehole wall.
As a consequence of this
nested arrangement a relatively large borehole diameter is required at the
upper part of the wellbore.
Such a large borehole diameter involves increased costs due to heavy casing
handling equipment, large
drill bits and increased volumes of drilling fluid and drill cuttings.
Moreover, increased drilling rig time is
involved due to required cement pumping, cement hardening, required equipment
changes due to large
variations in hole diameters drilled in the course of the well, and the large
volume of cuttings drilled and
removed.
[006] The present invention is directed to overcoming one or more of the
limitations of the existing
procedures for forming wellbore casings.
Summary
[007] According to one aspect of the present invention, a system for lining a
wellbore casing is provided
that includes a tubular support member defining a first passage, a tubular
expansion cone defining a
second passage fluidicly coupled to the first passage coupled to an end of the
tubular support member
and comprising a tapered end, a tubular liner coupled to and supported by the
tapered end of the tubular
expansion cone, and a shoe defining a valveable passage coupled to an end of
the tubular liner, wherein
the tubular liner includes one or more expandable tubular members that each
include a tubular body
comprising an intermediate portion and first and second expanded end portions
coupled to opposing ends
of the intermediate portion, and a sealing member coupled to the exterior
surface of the intermediate
portion, and one or more other tubular members coupled to the expandable
tubular members, wherein
the inside diameters of the other tubular members are greater than or equal to
the outside diameter of the
tubular expansion cone.
[008] According to another aspect of the present invention, a method of lining
a wellbore casing is
provided that includes positioning a tubular liner within the wellbore casing,
and radially expanding one or
more discrete portions of the tubular liner into engagement with the wellbore
casing.
[009] According to another aspect of the present invention, a system for
lining a wellbore casing is
provided that includes means for positioning a tubular liner within the
wellbore casing, and means for
radially expanding one or more discrete portions of the tubular liner into
engagement with the wellbore
casing. In an exemplary embodiment, a plurality of discrete portions of the
tubular liner are radially
expanded into engagement with the wellbore casing.
[0010] According to another aspect of the present invention, an apparatus is
provided that includes a
subterranean formation defining a borehole, a casing positioned in and coupled
to the borehole, and a
tubular liner positioned in and coupled to the casing at one or more discrete
locations.
Brief Description of the Drawings
[0011] Fig. 1 a is a cross sectional illustration of the placement of an
illustrative embodiment of a system
for lining a wellbore casing within a borehole having a preexisting wellbore
casing.
[0012] Fig. 1 b is a cross sectional illustration of the system of Fig. 1 a
during the injection of a fluidic
material into the tubular support member.
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[0013] Fig. 1 c is a cross sectional illustration of the system of Fig. 1 b
during the pressurization of the
interior portion of the shoe after sealing off the valveable fluid passage of
the shoe.
[0014] Fig. 1 d is a cross sectional illustration of the system of Fig. 1 c
during the continued injection of
the fluidic material into the tubular support member.
[0015] Fig. 1 e is a cross sectional illustration of the system of Fig. 1 d
after the completion of the radial
expansion and plastic deformation of the expandable tubular members.
[0016] Fig. 1f is a cross sectional illustration of the system of Fig. 1e
after machining the bottom central
portion of the shoe.
[0017] Fig. 2 is a cross sectional illustration of an illustrative embodiment
of the expandable tubular
members of the system of Fig. 1 a.
[0018] Fig. 3 is a flow chart illustration of an illustrative embodiment of a
method for manufacturing the
expandable tubular member of Fig. 2.
[0019] Fig. 4a is a cross sectional illustration of an illustrative embodiment
of the upsetting of the ends of
a tubular member.
[0020] Fig. 4b is a cross sectional illustration of the expandable tubular
member of Fig. 4a after radially
expanding and plastically deforming the ends of the expandable tubular member.
[0021] Fig. 4c is a cross sectional illustration of the expandable tubular
member of Fig. 4b after forming
threaded connections on the ends of the expandable tubular member.
[0022] Fig. 4d is a cross sectional illustration of the expandable tubular
member of Fig. 4c after coupling
sealing members to the exterior surface of the intermediate unexpanded portion
of the expandable
tubular member.
[0023] Fig. 5 is a cross-sectional illustration of an exemplary embodiment ofa
tubular expansion cone.
[0024] Fig. 6 is a cross-sectional illustration of an exemplary embodiment
of'a tubular expansion cone.
Description of the Illustrative Embodiments
[0025] Referring initially to Fig. 1 a, the reference numeral 10 refers, in
general, to a system for lining a
wellbore casing that includes a tubular support member 12 that defines a
passage 12a. A tubular
expansion cone 14 that defines a passage 14a is coupled to an end of the
tubular support member 12. In
an exemplary embodiment, the tubular expansion cone 14 includes a tapered
outer surface 14b for
reasons to be described. A pre-expanded end 16a of a first expandable tubular
member 16 that defines a
passage 16b is adapted to mate with and be supported by the tapered outer
surface 14b of the tubular
expansion cone 14. The first expandable tubular member 16 further includes an
unexpanded
intermediate portion 16c, another pre-expanded end 16d, and a sealing member
16e coupled to the
exterior surface of the unexpanded intermediate portion. In an exemplary
embodiment, the inside and
outside diameters of the pre-expanded ends, 16a and 16d, of the first
expandable tubular member 16 are
greater than the inside and outside diameters of the unexpanded intermediate
portion 16c. An end 18a of
a shoe 18 that defines a passage 18b and a valveable passage 18c is coupled to
the pre-expanded end
16a of the first expandable tubular member 16 by a conventional threaded
connection.
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[0026] An end 20a of a tubular member 20 that defines a passage 20b is coupled
to the other pre-
expanded end 16d of the first expandable tubular member 16 by a conventional
threaded connection.
Another end 20c of the tubular member 20 is coupled to an end 22a of a tubular
member 22 that defines
a passage 22b by a conventional threaded connection. A pre-expanded end 24a of
a second expandable
tubular member 24 that defines a passage 24b is coupled to the other end 22c
of the tubular member 22.
The second expandable tubular member 24 further includes an unexpanded
intermediate portion 24c,
another pre-expanded end 24d, and a sealing member 24e coupled to the exterior
surface of the
unexpanded intermediate portion. In an exemplary embodiment, the inside and
outside diameters of the
pre-expanded ends, 24a and 24d, of the second expandable tubular member 24 are
greater than the
inside and outside diameters of the unexpanded intermediate portion 24c.
[0027] An end 26a of a tubular member 26 that defines a passage 26b is coupled
to the other pre-
expanded end 24d of the second expandable tubular member 24 by a conventional
threaded connection.
Another end 26c of the tubular member 26 is coupled to an end 28a of a tubular
member 28 that defines
a passage 28b by a conventional threaded connection. A pre-expanded end 30a of
a third expandable
tubular member 30 that defines a passage 30b is coupled to the other end 28c
of the tubular member 28.
The third expandable tubular member 30 further includes an unexpanded
intermediate portion 30c,
another pre-expanded end 30d, and a sealing member 30e coupled to the exterior
surface of the
unexpanded intermediate portion. In an exemplary embodiment, the inside and
outside diameters of the
pre-expanded ends, 30a and 30d, of the third expandable tubular member 30 are
greater than the inside
and outside diameters of the unexpanded intermediate portion 30c.
[0028] In an exemplary embodiment, the inside and outside diameters of the pre-
expanded ends, 16a,
16d, 24a, 24d, 30a and 30d, of the expandable tubular members, 16, 24, and 30,
and the tubular
members 20, 22, 26, and 28, are substantially equal. In several exemplary
embodiments, the sealing
members, 16e, 24e, and 30e, of the expandable tubular members, 16, 24, and 30,
respectively, further
include anchoring elements for engaging the wellbore casing 104. In several
exemplary embodiments,
the tubular members, 20, 22, 26, and 28, are conventional tubular members
having threaded end
connections suitable for use in an oil or gas well, an underground pipeline,
or as a structural support.
[0029] In an exemplary embodiment, as illustrated in Fig. 1 a, the system 10
is initially positioned in a
borehole 100 formed in a subterranean formation 102 that includes a pre-
existing wellbore casing 104.
The borehole 100 may be positioned in any orientation from vertical to
horizontal. Furthermore, the
wellbore casing 104 may be, for example, a wellbore casing for an oil or gas
well, an underground
pipeline, or a structural support. In an exemplary embodiment, the upper end
of the tubular support
member 12 may be supported in a conventional manner using, for example, a slip
joint, or equivalent
device in order to permit upward movement of the tubular support member and
tubular expansion cone
14 relative to one or more of the expandable tubular members, 16, 24, and 30,
and tubular members, 20,
22, 26, and 28.
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[0030] In an exemplary embodiment, as illustrated in Fig. 1 b, a fluidic
material 106 is then injected into
the system 10, through the passages, 12a and 14a, of the tubular support
member 12 and tubular
expansion cone 14, respectively. The fluidic material 106 then passes into the
passages, 18b and 18c, of
the shoe 18 into the borehole 100.
[0031] In an exemplary embodiment, as illustrated in Fig. 1c, a ball 108, plug
or other equivalent device
is then introduced into the. injected fluidic material 106. The ball 108 will
then pass through the passages,
12a, 14a, and 18b, of the tubular support member 12, the tubular expansion
cone 14, and the shoe 18,
respectively, and will then be positioned within the valveable passage 18c of
the shoe. In this manner,
the valveable passage 18c of the shoe 18 is closed thereby permitting the
passage 18b of the shoe below
the tubular expansion cone 14 to be pressurized by the continued injection of
the fluidic material 106.
[0032] In an exemplary embodiment, as illustrated in Fig. 1d, the continued
injection of the fluidic
material 106 through the passages, 12a and 14a, of the tubular support member
12 and the tubular
expansion cone 14, respectively, pressurizes the passage 18b of the shoe 18
below the tubular
expansion cone thereby radially expanding and plastically deforming the
expandable tubular member 16
off of the tapered external surface 14b of the tubular expansion cone 14. In
particular, the intermediate
non pre-expanded portion 16c of the expandable tubular member 16 is radially
expanded and plastically
deformed off of the tapered external surface 14b of the tubular expansion cone
14. As a result, the
sealing member 16e engages the interior surface of the wellbore casing 104.
Consequently, the radially
expanded intermediate portion 16c of the expandable tubular member 16 is
thereby coupled to the
weilbore casing 104. In an exemplary embodiment, the radially expanded
intermediate portion 16c of the
expandable tubular member 16 is also thereby anchored to the wellbore casing
104.
[0033] The continued injection of the fluidic material 106 through the
passages, 12a and 14a, of the
tubular support member 12 and the tubular expansion cone 14, respectively,
will then displace the tubular
expansion cone 14 upwardly into engagement with the pre-expanded end 24a of
the second expandable
tubular member 24.
[0034] In an exemplary embodiment, as illustrated in Fig. le, the continued
injection of the fluidic
material 106 through the passages, 12a and 14a, of the tubular support member
12 and tubular
expansion cone 14, respectively, will then pressurize the passages 18b, 16b,
20b and 22b below the
tubular expansion cone thereby radially expanding and plastically deforming
the second expandable
tubular member 24 off of the tapered external surface 14b of the tubular
expansion cone 14. In particular,
the intermediate non pre-expanded portion 24c of the second expandable tubular
member 24 is radially
expanded and plastically deformed off of the tapered external surface 14b of
the tubular expansion cone
14. As a result, the sealing member 24e engages the interior surface of the
wellbore casing 104.
Consequently, the radially expanded intermediate portion 24c of the second
expandable tubular member
24 is thereby coupled to the wellbore casing 104. In an exemplary embodiment,
the radially expanded
intermediate portion 24c of the second expandable tubular member 24 is also
thereby anchored to the
wellbore casing 104.
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[0035] The continued injection of the fluidic material 106 through the
passages, 12a and 14a, of the
tubular support member 12 and the tubular expansion cone 14, respectively,
will then displace the tubular
expansion cone 14 upwardly into engagement with the pre-expanded end 30a of
the third expandable
tubular member 30.
[0036] The continued injection of the fluidic material 106 through the
passages, 12a and 14a, of the
tubular support member 12 and tubular expansion cone 14, respectively, will
then pressurize the
passages 18b, 16b, 20b, 22b, 24b, 26b, and 28b below the tubular expansion
cone thereby radially
expanding and plastically deforming the third expandable tubular member 30 off
of the tapered external
surface 14b of the tubular expansion cone 14. In particular, the intermediate
non pre-expanded portion
30c of the third expandable tubular member 30 is radially expanded and
plastically deformed off of the
tapered external surface 14b of the tubular expansion cone 14. As a result,
the sealing member 30e
engages the interior surface of the wellbore casing 104. Consequently, the
radially expanded
intermediate portion 30c of the third expandable tubular member 30 is thereby
coupled to the wellbore
casing 104. In an exemplary embodiment, the radially expanded intermediate
portion 30c of the third
expandable tubular member 30 is also thereby anchored to the wellbore casing
104.
[0037] In an exemplary embodiment, during the injection of the fluidic
material 106 through the
passages, 12a and 14a, of the tubular support member 12 and the tubular
expansion cone 14,
respectively, the tubular support member 12 and tubular expansion cone 14 are
displaced upwardly
relative to the expandable tubular members, 16, 24, and 30, and the tubular
members, 20, 22, 26, and 28,
by applying an upward axial force to the upper end of the tubular support
member.
[0038] After completing the radial expansion and plastic deformation of the
third expandable tubular
member 30, the tubular support member 12 and the tubular expansion cone 14 are
removed from the
wellbore 100.
[0039] In an exemplary embodiment, as illustrated in Fig. If, the lower
central portion of the shoe 18 is
then removed using a conventional milling device.
[0040] Thus, during the operation of the system 10, the intermediate non pre-
expanded portions, 16c,
24c, and 30c, of the expandable tubular members, 16, 24, and 30, respectively,
are radially expanded
and plastically deformed by the pressurization of the interior passages, 18a,
16b, 20b, 22b, 24b, 26b,
28b, and 30b, of the shoe 18, the expandable tubular member 16, the tubular
members, 20 and 22, the
expandable tubular member 24, the tubular members, 26 and 28, and the
expandable tubular member
30, respectively, below the tubular expansion cone 14. As a result, the
sealing members, 16e, 24e, and
30e, are displaced in the radial direction into engagement with the wellbore
casing 104 thereby coupling
the shoe 18, the expandable tubular member 16, the tubular members, 20 and 22,
the expandable tubular
member 24, the tubular members, 26 and 28, and the expandable tubular member
30 to the wellbore
casing. Furthermore, as a result, the expandable connections between the
expandable tubular members,
16, 24, and 30, the shoe 18, and the tubular members, 20, 22, 26, and 28, do
not have to be expandable
connections thereby providing significant cost savings. Furthermore, in the
system 10, the tubular
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members 20, 22, 26, and 28 are interleaved among the expandable tubular
members, 16, 24, and 30. As
a result, because only the intermediate non pre-expanded portions, 16c, 24c,
and 30c, of the expandable
tubular members, 16, 24, and 30, respectively, are radially expanded and
plastically deformed, the tubular
members, 20, 22, 26, and 28 can be conventional tubular members thereby
significantly reducing the cost
and complexity of the system 10. Moreover, because only the intermediate non
pre-expanded portions,
16c, 24c, and 30c, of the expandable tubular members, 16, 24, and 30,
respectively, are radially
expanded and plastically deformed, the number and length of the interleaved
tubular members, 20, 22,
26, and 28 can be much greater than the number and length of the expandable
tubular members. In an
exemplary embodiment, the total length of the intermediate non pre-expanded
portions, 16c, 24c, and
30c, of the expandable tubular members, 16, 24, and 30, is approximately 200
feet, and the total length of
the tubular members, 20, 22, 26, and 28, is approximately 3800 feet.
Consequently, in an exemplary
embodiment, a liner having a total length of approximately 4000 feet is
coupled to a wellbore casing by
radially expanding and plastically deforming a total length of only
approximately 200 feet.
[0041] Furthermore, the sealing members 16e, 24e, and 30e, of the expandable
tubular members, 16,
24, and 30, respectively, are used to couple the expandable tubular members
and the tubular members,
20, 22, 26, and 28 to the weilbore casing 104, the radial gap between the
tubular members, the
expandable tubular members, and the wellbore casing 104 may be large enough to
effectively eliminate
the possibility of damage to the expandable tubular members and tubular
members during the placement
of the system 10 within the weilbore casing.
[0042] In an exemplary embodiment, after the sealing member 16e of the
expandable tubular member
16 has been radially expanded into engagement with the weilbore casing 104,
the expandable tubular
members, 24 and 30, are radially expanded and plastically deformed by
injecting the fluidic material 106
and applying an upward axial force to the tubular support member 12 and
tubular expansion cone 14. In
this manner, radial expansion and plastic deformation of the expandable
tubular members, 24 and 30,
may be enhanced.
[0043] In an exemplary embodiment, after the sealing member 16e of the
expandable tubular member
16 has been radially expanded into engagement with the wellbore casing 104,
the expandable tubular
members, 24 and 30, are radially expanded and plastically deformed by only
applying an upward axial
force to the tubular support member 12 and tubular expansion cone 14. In this
manner, radial expansion
and plastic deformation of the expandable tubular members, 24 and 30, may be
provided without the
further continued injection of the fluidic material 106.
[0044] In an exemplary embodiment, the pre-expanded ends, 16a, 16d, 24a, 24d,
30a, and 30d, of the
expandable tubular members, 16, 24, and 30, respectively, and the tubular
members, 20, 22, 26, and 28,
have outside diameters and wall thicknesses of 8.375 inches and 0.350 inches,
respectively; prior to the
radial expansion, the intermediate non pre-expanded portions, 16c, 24c, and
30c, of the expandable
tubular members, 16, 24, and 30, respectively, have outside diameters of 7.625
inches; the tubular
members, 20, 22, 26, and 28, have inside diameters of 7.675 inches; after the
radial expansion, the inside
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diameters of the intermediate portions, 16c, 24c, and 30c, of the expandable
tubular members, 16, 24,
and 30, are equal to 7.675 inches; and the wellbore casing 104 has an inside
diameter of 8.755 inches.
[0045] In an exemplary embodiment, the pre-expanded ends, 16a, 16d, 24a, 24d,
30a, and 30d, of the
expandable tubular members, 16, 24, and 30, respectively, and the tubular
members, 20, 22, 26, and 28,
have outside diameters and wall thicknesses of 4.500 inches and 0.250 inches,
respectively; prior to the
radial expansion, the intermediate non pre-expanded portions, 16c, 24c, and
30c, of the expandable
tubular members, 16, 24, and 30, respectively, have outside diameters of 4.000
inches; the tubular
members, 20, 22, 26, and 28, have inside diameters of 4.000 inches; after the
radial expansion, the inside
diameters of the intermediate portions, 16c, 24c, and 30c, of the expandable
tubular members, 16, 24,
and 30, are equal to 4.000 inches; and the wellbore casing 104 has an inside
diameter of 4.892 inches.
[0046] In an exemplary embodiment, the system 10 is used to form or repair a
wellbore casing, a
pipeline, or a structural support.
[0047] Referring now to Fig. 2, an exemplary embodiment of an expandable
tubular member 200 will
now be described. The tubular member 200 defines an interior region 200a and
includes a first end 200b
including a first threaded connection 200ba, a first tapered portion 200c, an
intermediate portion 200d, a
second tapered portion 200e, and a second end 200f including a second threaded
connection 200fa. The
tubular member 200 further preferably includes an intermediate sealing member
200g that is coupled to
the exterior surface of the intermediate portion 200d.
[0048] In an exemplary embodiment, the tubular member 200 has a substantially
annular cross section.
The tubular member 200 may be fabricated from any number of conventional
commercially available
materials such as, for example, Oilfield Country Tubular Goods (OCTG), 13
chromium steel
tubing/casing, or L83TM, J55TM, or P110 API TM casing.
[0049] In an exemplary embodiment, the interior 200a of the tubular member 200
has a substantially
circular cross section. Furthermore, in an exemplary embodiment, the interior
region 200a of the tubular
member includes a first inside diameter D1, an intermediate inside diameter
DINT, and a second inside
diameter D2. In an exemplary embodiment, the first and second inside
diameters, D, and D2, are
substantially equal. In an exemplary embodiment, the first and second inside
diameters, D, and D2, are
greater than the intermediate inside diameter DINT.
[0050] The first end 200b of the tubular member 200 is coupled to the
intermediate portion 200d by the
first tapered portion 200c, and the second end 200f of the tubular member is
coupled to the intermediate
portion by the second tapered portion 200e. In an exemplary embodiment, the
outside diameters of the
first and second ends, 200b and 200f, of the tubular member 200 is greater
than the outside diameter of
the intermediate portion 200d of the tubular member. The first and second
ends, 200b and 200f, of the
tubular member 200 include wall thicknesses, t, and t2, respectively. In an
exemplary embodiment, the
outside diameter of the intermediate portion 200d of the tubular member 200
ranges from about 75% to
98% of the outside diameters of the first and second ends, 200a and 200f. The
intermediate portion 200d
of the tubular member 200 includes a wall thickness tINT=
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[0051] In an exemplary embodiment, the wall thicknesses t1 and t2 are
substantially equal in order to
provide substantially equal burst strength for the first and second ends, 200a
and 200f, of the tubular
member 200. In an exemplary embodiment, the wall thicknesses, t1 and t2, are
both greater than the wall
thickness tINT in order to optimally match the burst strength of the first and
second ends, 200a and 200f, of
the tubular member 200 with the intermediate portion 200d of the tubular
member 200.
[0052] In an exemplary embodiment, the first and second tapered portions, 200c
and 200e, are inclined
at an angle, a, relative to the longitudinal direction ranging from about 0 to
30 degrees in order to
optimally facilitate the radial expansion of the tubular member 200. In an
exemplary embodiment, the first
and second tapered portions, 200c and 200e, provide a smooth transition
between the first and second
ends, 200a and 200f, and the intermediate portion 200d, of the tubular member
200 in order to minimize
stress concentrations.
[0053] The intermediate sealing member 200g is coupled to the outer surface of
the intermediate portion
200d of the tubular member 200. In an exemplary embodiment, the intermediate
sealing member 200g
seals the interface between the intermediate portion 200d of the tubular
member 200 and the interior
surface of a wellbore casing 205 after the radial expansion and plastic
deformation of the intermediate
portion 200d of the tubular member 200. In an exemplary embodiment, the
intermediate sealing member
200g has a substantially annular cross section. In an exemplary embodiment,
the outside diameter of the
intermediate sealing member 200g is selected to be less than the outside
diameters of the first and
second ends, 200a and 200f, of the tubular member 200 in order to optimally
protect the intermediate
sealing member 200g during placement of the tubular member 200 within the
wellbore casings 205. The
intermediate sealing member 200g may be fabricated from any number of
conventional commercially
available materials such as, for example, thermoset or thermoplastic polymers.
In an exemplary
embodiment, the intermediate sealing member 200g is fabricated from thermoset
polymers in order to
optimally seal the radially expanded intermediate portion 200d of the tubular
member 200 with the
wellbore casing 205. In several alternative embodiments, the sealing member
200g includes one or more
rigid anchors for engaging the wellbore casing 205 to thereby anchor the
radially expanded and plastically
deformed intermediate portion 200d of the tubular member 200 to the wellbore
casing.
[0054] Referring to Figs. 3, and 4a to 4d, in an exemplary embodiment, the
tubular member 200 is
formed by a process 300 that includes the steps of: (1) upsetting both ends of
a tubular member in step
305; (2) expanding both upset ends of the tubular member in step 310; (3)
stress relieving both expanded
upset ends of the tubular member in step 315; (4) forming threaded connections
in both expanded upset
ends of the tubular member in step 320; and (5) putting a sealing material on
the outside diameter of the
non-expanded intermediate portion of the tubular member in step 325.
[0055] As illustrated in FIG. 4a, in step 305, both ends, 400a and 400b, of a
tubular member 400 are
upset using conventional upsetting methods. The upset ends, 400a and 400b, of
the tubular member 400
include the wall thicknesses t, and t2. The intermediate portion 400c of the
tubular member 400 includes
the wall thickness tINT and the interior diameter DINT. In an exemplary
embodiment, the wall thicknesses t,
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and t2 are substantially equal in order to provide burst strength that is
substantially equal along the entire
length of the tubular member 400. In an exemplary embodiment, the wall
thicknesses t, and t2 are both
greater than the wall thickness tINT in order to provide burst strength that
is substantially equal along the
entire length of the tubular member 400, and also to optimally facilitate the
formation of threaded
connections in the first and second ends, 400a and 400b.
[0056] As illustrated in Fig. 4b, in steps 310 and 315, both ends, 400a and
400b, of the tubular member
400 are radially expanded using conventional radial expansion methods, and
then both ends, 400a and
400b, of the tubular member are stress relieved. The radially expanded ends,
400a and 400b, of the
tubular member 400 include the interior diameters D, and D2. In an exemplary
embodiment, the interior
diameters D, and D2 are substantially equal in order to provide a burst
strength that is substantially equal.
In an exemplary embodiment, the ratio of the interior diameters D, and D2 to
the interior diameter DINT
ranges from about 100% to 120% in order to faciliate the subsequent radial
expansion of the tubular
member 400.
[0057] In a preferred embodiment, the relationship between the wall
thicknesses t,, t2, and tINT of the
tubular member 400; the inside diameters D,, D2 and DINT of the tubular member
400; the inside diameter
Dwellbore of the wellbore casing that the tubular member 400 will be inserted
into; and the outside diameter
Dcone of the expansion cone that will be used to radially expand the tubular
member 400 within the
wellbore casing is given by the following expression:
Dwellbore - 2* ti > DI >- tl [(ti - tINT)* Dcone + trw,* DINT ] (1)
where t, = t2; and
D,=D2.
[0058] By satisfying the relationship given in equation (1), the expansion
forces placed upon the tubular
member 400 during the subsequent radial expansion process are substantially
equalized. More
generally, the relationship given in equation (1) may be used to calculate the
optimal geometry for the
tubular member 400 for subsequent radial expansion and plastic deformation of
the tubular member 400
for fabricating and/or repairing a wellbore casing, a pipeline, or a
structural support.
[0059] As illustrated in FIG. 4c, in step 320, conventional threaded
connections, 400d and 400e, are
formed in both expanded ends, 400a and 400b, of the tubular member 400. In an
exemplary
embodiment, the threaded connections, 400d and 400e, are provided using
conventional processes for
forming pin and box type threaded connections available from Atlas-Bradford.
[0060] As illustrated in Fig. 4d, in step 325, a sealing member 400f is then
applied onto the outside
diameter of the non-expanded intermediate portion 400c of the tubular member
400. The sealing
member 400f may be applied to the outside diameter of the non-expanded
intermediate portion 400c of
the tubular member 400 using any number of conventional commercially available
methods. In a
preferred embodiment, the sealing member 400f is applied to the outside
diameter of the intermediate
portion 400c of the tubular member 400 using commercially available chemical
and temperature resistant
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adhesive bonding.
[0061] In an exemplary embodiment, the expandable tubular members, 16, 24, and
30, of the system 10
are substantially identical to, and/or incorporate one or more of the
teachings of, the tubular members 200
and 400.
[0062] Referring to Fig. 5, an exemplary embodiment of tubular expansion cone
500 for radially
expanding the tubular members 16, 24, 30, 200 and 400 will now be described.
The expansion cone 500
defines a passage 500a and includes a front end 505, a rear end 510, and a
radial expansion section
515.
[0063] In an exemplary embodiment, the radial expansion section 515 includes a
first conical outer
surface 520 and a second conical outer surface 525. The first conical outer
surface 520 includes an
angle of attack a, and the second conical outer surface 525 includes an angle
of attack 02. In an
exemplary embodiment, the angle of attack a, is greater than the angle of
attack a2. In this manner, the
first conical outer surface 520 radially overexpands the intermediate
portions, 16c, 24c, 30c, 200d, and
400c, of the tubular members, 16, 24, 30, 200, and 400, and the second conical
outer surface 525 radially
overexpands the pre-expanded first and second ends, 16a and 16d, 24a and 24d,
30a and 30d, 200b and
200f, and 400a and 400b, of the tubular members, 16, 24, 30, 200 and 400. In
an exemplary
embodiment, the first conical outer surface 520 includes an angle of attack a,
ranging from about 8 to 20
degrees, and the second conical outer surface 525 includes an angle of attack
a2 ranging from about 4 to
15 degrees in order to optimally radially expand and plastically deform the
tubular members, 16, 24, 30,
200 and 400. More generally, the expansion cone 500 may include 3 or more
adjacent conical outer
surfaces having angles of attack that decrease from the front end 505 of the
expansion cone 500 to the
rear end 510 of the expansion cone 500.
[0064] Referring to Fig. 6, another exemplary embodiment of a tubular
expansion cone 600 defines a
passage 600a and includes a front end 605, a rear end 610, and a radial
expansion section 615. In an
exemplary embodiment, the radial expansion section 615 includes an outer
surface having a substantially
parabolic outer profile thereby providing a paraboloid shape. In this manner,
the outer surface of the
radial expansion section 615 provides an angle of attack that constantly
decreases from a maximum at
the front end 605 of the expansion cone 600 to a minimum at the rear end 610
of the expansion cone.
The parabolic outer profile of the outer surface of the radial expansion
section 615 may be formed using a
plurality of adjacent discrete conical sections and/or using a continuous
curved surface. In this manner,
the region of the outer surface of the radial expansion section 615 adjacent
to the front end 605 of the
expansion cone 600 may optimally radially overexpand the intermediate
portions, 16c, 24c, 30c, 200d,
and 400c, of the tubular members, 16, 24, 30, 200, and 400, while the region
of the outer surface of the
radial expansion section 615 adjacent to the rear end 610 of the expansion
cone 600 may optimally
radially overexpand the pre-expanded first and second ends, 16a and 16d, 24a
and 24d, 30a and 30d,
200b and 200f, and 400a and 400b, of the tubular members, 16, 24, 30, 200 and
400. In an exemplary
embodiment, the parabolic profile of the outer surface of the radial expansion
section 615 is selected to
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provide an angle of attack that ranges from about 8 to 20 degrees in the
vicinity of the front end 605 of the
expansion cone 6800 and an angle of attack in the vicinity of the rear end 610
of the expansion cone 600
from about 4 to 15 degrees.
[0065] In an exemplary embodiment, the tubular expansion cone 14 of the system
10 is substantially
identical to the expansion cones 500 or 600, and/or incorporates one or more
of the teachings of the
expansion cones 500 and/or 600.
[0066] In several alternative embodiments, a conventional rotary expansion
system such as, for
example, those commercially available from Weatherford International may be
substituted for, or used in
combination with the expansion cones 14, 500, and/or 600 above.
[0067] In several alternative embodiments, conventional expansion systems may
be substituted for, or
used in combination with the expansion cones 14, 500, and/or 600 above.
[0068] A system for lining a wellbore casing has been described that includes
a tubular support member
defining a first passage, a tubular expansion cone defining a second passage
fluidicly coupled to the first
passage coupled to an end of the tubular support member and comprising a
tapered end, a tubular liner
coupled to and supported by the tapered end of the tubular expansion cone, and
a shoe defining a
valveable passage coupled to an end of the tubular liner, wherein the tubular
liner includes one or more
expandable tubular members that each include a tubular body comprising an
intermediate portion and
first and second expanded end portions coupled to opposing ends of the
intermediate portion, and a
sealing member coupled to the exterior surface of the intermediate portion,
and one or more other tubular
members coupled to the expandable tubular members, wherein the inside
diameters of the other tubular
members are greater than or equal to the outside diameter of the tubular
expansion cone. In an
exemplary embodiment, the wall thicknesses of the first and second expanded
end portions are greater
than the wall thickness of the intermediate portion. In an exemplary
embodiment, each expandable
tubular member further includes a first tubular transitionary member coupled
between the first expanded
end portion and the intermediate portion, and a second tubular transitionary
member coupled between
the second expanded end portion and the intermediate portion, wherein the
angles of inclination of the
first and second tubular transitionary members relative to the intermediate
portion ranges from about 0 to
30 degrees. In an exemplary embodiment, the outside diameter of the
intermediate portion ranges from
about 75 percent to about 98 percent of the outside diameters of the first and
second expanded end
portions. In an exemplary embodiment, the burst strength of the first and
second expanded end portions
is substantially equal to the burst strength of the intermediate tubular
section. In an exemplary
embodiment, the ratio of the inside diameters of the first and second expanded
end portions to the interior
diameter of the intermediate portion ranges from about 100 to 120 percent. In
an exemplary
embodiment, the relationship between the wall thicknesses t1, t2, and tINT of
the first expanded end
portion, the second expanded end portion, and the intermediate portion,
respectively, of the expandable
tubular members, the inside diameters D1, D2 and DINT of the first expanded
end portion, the second
expanded end portion, and the intermediate portion, respectively, of the
expandable tubular members,
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and the inside diameter D1Neõbore of the wellbore casing that the expandable
tubular member will be
inserted into, and the outside diameter Dcone of the expansion cone that will
be used to radially expand the
expandable tubular member within the wellbore casing is given by the following
expression:
Dwellbore - 2# ti - D1 >_ tl I('] - tõT~* D,o. + 'I, DIN.,;
[0069] wherein t, = t2; and wherein D, = D2. In an exemplary embodiment, the
tapered end of the tubular
expansion cone includes a plurality of adjacent discrete tapered sections. In
an exemplary embodiment,
the angle of attack of the adjacent discrete tapered sections increases in a
continuous manner from one
end of the tubular expansion cone to the opposite end of the tubular expansion
cone. In an exemplary
embodiment, the tapered end of the tubular expansion cone includes an
paraboloid body. In an
exemplary embodiment, the angle of attack of the outer surface of the
paraboloid body increases in a
continuous manner from one end of the paraboloid body to the opposite end of
the paraboloid body. In
an exemplary embodiment, the tubular liner includes a plurality of expandable
tubular members, and the
other tubular members are interleaved among the expandable tubular members.
[0070] A method of lining a wellbore casing has also been described that
includes positioning a tubular
liner within the wellbore casing, and radially expanding one or more discrete
portions of the tubular liner
into engagement with the wellbore casing. In an exemplary embodiment, a
plurality of discrete portions of
the tubular liner are radially expanded into engagement with the wellbore
casing. In an exemplary
embodiment, the remaining portions of the tubular liner are not radially
expanded. In an exemplary
embodiment, the discrete portions of the tubular liner are radially expanded
by injecting a fluidic material
into the tubular liner. In an exemplary embodiment, the tubular liner includes
a plurality of tubular
members; and wherein one or more of the tubular members are radially expanded
into engagement with
the wellbore casing and one or more of the tubular members are not radially
expanded into engagement
with the wellbore casing. In an exemplary embodiment, the tubular members that
are radially expanded
into engagement with the wellbore casing include a portion that is radially
expanded into engagement
with the wellbore casing and a portion that is not radially expanded into
engagement with the wellbore
casing. In an exemplary embodiment, the tubular liner includes one or more
expandable tubular
members that each include a tubular body comprising an intermediate portion
and first and second
expanded end portions coupled to opposing ends of the intermediate portion,
and a sealing member
coupled to the exterior surface of the intermediate portion, and one or more
other tubular members
coupled to the expandable tubular members, wherein the inside diameters of the
other tubular members
are greater than or equal to the maximum inside diameters of the expandable
tubular members. In an
exemplary embodiment, the tubular liner includes a plurality of expandable
tubular members, and the
other tubular members are interleaved among the expandable tubular members.
[0071] A system for lining a wellbore casing has also been described that
includes means for positioning
a tubular liner within the wellbore casing, and means for radially expanding
one or more discrete portions
of the tubular liner into engagement with the wellbore casing. In an exemplary
embodiment, a plurality of
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discrete portions of the tubular liner are radially expanded into engagement
with the wellbore casing. In
an exemplary embodiment, the remaining portions of the tubular liner are not
radially expanded. In an
exemplary embodiment, the discrete portions of the tubular liner are radially
expanded by injecting a
fluidic material into the tubular liner. In an exemplary embodiment, the
tubular liner includes a plurality of
tubular members; and wherein one or more of the tubular members are radially
expanded into
engagement with the wellbore casing and one or more of the tubular members are
not radially expanded
into engagement with the wellbore casing. In an exemplary embodiment, the
tubular members that are
radially expanded into engagement with the wellbore casing comprise a portion
that is radially expanded
into engagement with the wellbore casing and a portion that is not radially
expanded into engagement
with the wellbore casing.
(0072] An apparatus has also been described that includes a subterranean
formation defining a
borehole, a casing positioned in and coupled to the borehole, and a tubular
liner positioned in and
coupled to the casing at one or more discrete locations. In an exemplary
embodiment, the tubular liner is
coupled to the casing at a plurality of discrete locations. In an exemplary
embodiment, the tubular liner is
coupled to the casing by a process that includes positioning the tubular liner
within the casing, and
radially expanding one or more discrete portions of the tubular liner into
engagement with the casing. In
an exemplary embodiment, a plurality of discrete portions of the tubular liner
are radially expanded into
engagement with the casing. In an exemplary embodiment, the remaining portions
of the tubular liner are
not radially expanded. In an exemplary embodiment, the discrete portions of
the tubular liner are radially
expanded by injecting a fluidic material into the tubular liner. In an
exemplary embodiment, the tubular
liner includes a plurality of tubular members; and wherein one or more of the
tubular members are radially
expanded into engagement with the casing and one or more of the tubular
members are not radially
expanded into engagement with the casing. In an exemplary embodiment, the
tubular members that are
radially expanded into engagement with the casing comprise a portion that is
radially expanded into
engagement with the casing and a portion that is not radially expanded into
engagement with the casing.
In an exemplary embodiment, the tubular liner includes one or more expandable
tubular members that
each include a tubular body comprising an intermediate portion and first and
second expanded end
portions coupled to opposing ends of the intermediate portion, and a sealing
member coupled to the
exterior surface of the intermediate portion, and one or more other tubular
members coupled to the
expandable tubular members, wherein the inside diameters of the other tubular
members are greater than
or equal to the maximum inside diameters of the expandable tubular members. In
an exemplary
embodiment, the tubular liner includes a plurality of expandable tubular
members, and the other tubular
members are interleaved among the expandable tubular members.
[0073] It is understood that variations may be made in the foregoing without
departing from the scope of
the invention. For example, the system 10 may be used to form or repair a
wellbore casing, an
underground pipeline, a structural support, or a tubing. Furthermore, the
system 10 may include one or
more expandable tubular members and one or more other tubular members. In
addition, the system 10
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may include a plurality of expandable tubular members, and the other tubular
members may be
interleaved among the expandable tubular members.
[0074] Although illustrative embodiments of the invention have been shown and
described, a wide range
of modification, changes and substitution is contemplated in the foregoing
disclosure. In some instances,
some features of the present invention may be employed without a corresponding
use of the other
features. Accordingly, it is appropriate that the appended claims be construed
broadly and in a manner
consistent with the scope of the invention.
